Carton construction



Dec. 14, 1965 R. M.-KUHLMAN CARTON CONSTRUCTION 2 Sheets-Sheet 1 Filed July 25, 1963 INVENTOR.

Dec. 14, 1965 R. M. KUHLMAN 3,223,307

CARTON CONSTRUCTION Filed July 25, 1963 2 Sheets-Sheet 2 United States Patent 3,223,307 CARTON CONSTRUCTION Roy M. Kuhlman, Crown Point, Ind, assignor, by mesne assignments, to PKG. Corporation, Evanston, Ill., a corporation of Delaware Filed July 25, 1963, Ser. No. 297,515 11 Claims. (Cl. 2229-28) This invention relates to a carton construction and more particularly to a foldable, yet separable, carton suitable for use in the packaging of eggs or other similar type fragile articles. The carton, when separated, forms complemental sections, each of which may have a configuration similar to the carton configuration shown in United States Patent No. 2,983,427.

In the retailing of eggs, for example, in supermarkets or the like, it has become customary to sell such items in cartons of one dozen size. Such cartons are either of the conventional 3 x 4 or 2 x 6 style. in either case, the packing of eggs into the individual cartons normally occurs at a location remote from the retail outlet. Subsequent to the eggs being packed into individual cartons, a predetermined number of loaded cartons are then usually placed in large shipping cases for either storage or transporting to the retail outlet. Because of the amount of handling of the loaded cartons required before they eventually reach the ultimate buyer, the incidence of breakage is quite high. When breakage of an accommodated egg occurs, soiling or defacement of a portion of the accommodating carton results and in instances where the loaded cartons are arranged in stacked relation, soiling of the carton disposed therebeneath may also result.

Because of the unappealing appearance of a soiled egg carton, the retailer, upon encountering such a situation, is compelled to either remove from sale the loaded soiled carton; repack the remaining uncracked eggs in a new carton; or endeavor to separate the soiled portion of the carton from the remainder thereof and thereby sell the eggs in smaller quantities, e.g. in half dozen size cartons. Where a large quantity of eggs are handled by the retailer, it becomes impractical to attempt to repack the eggs in a new carton. Discarding the whole carton and its contents because of one or more of the accommodated eggs being cracked, is undesirable because of the waste and expense involved. Thus, the third alternative of separating the soiled portion of the carton from the remainder of the carton appears to be the most feasible solution.

Furthermore, in certain geographical areas there is a preference for purchasing eggs; for example, in quantities of a half dozen. In such a situation, the retailer for competitive reasons is disposed to otter such quantities for sale and thus, there is a need for a carton which can readily be converted into a half dozen size if the need arises.

Various separable cartons have heretofore been proposed in an effort to meet the aforenoted problems, however, because of certain design characteristics, these cartons, even before separation, are structurally weak or the resulting separated carton sections fail to provide adequate protection for the accommodated eggs. Furthermore, in many instances, the prior carton was of complex design involving awkward ma ipulations to eliect set-up thereof, or required an excessive amount of material to form the blank, thus increasing substantially the cost of such carton.

It is one of the objects therefore of this invention to provide a separable foldable carton which is readily capable of being set up either manually or by automatic or semi-automatic equipment.

It is a further object of this invention to provide a separable foldable carton which affords adequate protection to its accommodated articles regardless of whether the carton is separated in complemental sections or not.

It i a further object of this invention to provide a separable foldable carton wherein there is no sacrifice of structural stability by reason of separating the carton into complemental carton units.

It is a still further object of this invention to provide a separable foldable carton which is of inexpensive, yet sturdy, construction, and permits its contents to be readily observed by the potential customer.

I is a still further object of this invention to provide a separable foldable carton which may be readily, manually separated into complemental carton sections by the customer at the time of sale.

Further and additional objects will appear from the description, accompanying drawings, and appended claims.

In accordance with one embodiment of this invention a separable foldable carton is provided which includes a bottom side panels extending upwardly therefrom, and a plurality of bridging elements arranged in spaced substantially parallel relation and interconnecting corresponding upper marginal portions of the side panels. Foldably connected to the bridging elements and depending therefrom are divider panels, each of which has peripheral segments thereof in interlocking engagement with corresponding portions of the respective bridging elements. The divider panels, bottom, and side panels cooperate with one another to form at least one row of article-accommodating pockets. One of the bridging elements, intermediate the end bridging elements, has a pair of spaced substantially parallel divider panels depending therefrom. The portion of the said one bridging element disposed intermediate said pair of divider panels and the portions of said bottom and side panels disposed intermediate the planes of said pair of divider panels are provided with means for effecting separation or the carton into complemental sections. Each divider panel of said pair of divider panels forms an end wall of the complemental carton section.

For a more complete understanding of this invention reference should be made to the drawings wherein:

FIG. 1 is a plan view of the blank for the improved carton.

FIG. 2 is an enlarged perspective view of the improved carton.

FIG. 3 is a perspective view of the improved carton of FIG. 2 shown in the state of being separated into coinplemental carton sections.

FIG. 4 is a perspective view of the improved carton in a partial state of set-up.

Referring now to the drawings and more particularly to FIG. 1, a blank 10 formed of suitable fibreboard or cardboard material is shown. The blank in the illusstrated embodiment is provided with a plurality of spaced substantially parallel elongated foldlines, Illa-b, l2ab, and i3cb which are adapted to cooperate with one another so as to form a center section 14, a pair of side walls 15, a pair of bottom walls 16, and a pair of partition walls 17.

The center section 14, in turn, is provided with a plurality of spaced, similar foldlines 18, 20, 21, 22, 23, 24, 25, and 26 all of which are angularly arranged with respect to foldlines lla-b. Each foldline 18, and 2946 is of like configuration and includes a center portion, designated by a in each instance, and first end portions b which extend divergently from the ends of said center portion. The distal ends of the end portions b of each foldline, except foldlines 18 and 26, are interconnected by a curvilinear slit 27.

From the junctures 0 between portions a and b of each foldline 13 or 20-26 there extend divergently a pair of second end portions (1. The divergency of end portions d is less than that of end portions b and thus, end portions d are disposed between end portions b. Each end portion d extends from juncture c to slit 27, except in the case of foldlines 18 and 26 wherein the outer end limit of each portion d terminates at the periphery of the blank. A third pair of spaced substantially parallel end portions e extend from junctures c and are disposed at substantially right angles with respect to center portion a. The function of end portions 2 will be described more fully hereinafter.

The portions a, b, d and e of each foldline 18, or -26 cooperate with one another, when the blank is set up, to form a depending divider .panel 28, 3t), 31, 32, 33, 34, 35 or 36. By reason of the. pair of foldline end portions b and d, the opposite ends 28a, 30a, 31a, 32a, 33a, 34a, 35:: or 36a of each divider panel are angularly disposed with respect to the center portion 28b, 36b, 31b, 32b, 33b, 34b, 35b or 36b of the panel, see FIG. 4.

The lower marginal edge of each divider panel is provided with a short centrally disposed slot 37. In panels 30, 31, 34 and 35, an aperture 38 is also provided which is spaced from, but aligned with, the inner end of slot 37. The function of slots 37 and apertures 38 will become apparent from the description hereinafter.

It will be noted in FIG. 1 that center portions a of foldlines 22 and 23 are disposed in spaced, yet proximate, relation. Extending between and in parallel relation with respect to portions a of foldlines 22 and 23 is an elongated perforated or weakened line 40. Line 40, it will be noted in FIG. 1, extends through the side, bottom and partition walls of the blank, and as will be described more fully hereinafter serves as a means of separating the set-up carton 41, see FIG. 2, into two complemental carton sections or units 41a and 41b, see FIG. 3.

The remainder of the center section 14 of blank 10, when the divider panels assume their depending positions, as seen in FIGS. 2 and 4, forms a plurality of bridging elements 42, 43, 44, 45, 46, 47, and 48. The ends of each bridging element extend angularly downwardly from foldline portions e and terminate at foldlines 11a and 11b, and thus, serve to interconect corresponding upper marginal segments of side walls 15.

It will be noted in FIG. 1, that the bridging elements 42, 43, and 44, which are disposed to one side of center bridging eelment 45, each has an overhanging marginal edge thereof, formed by the slit 27, disposed inwardly toward the center bridging element 45. The same arrangement prevails with respect to bridging elements 46, 47, and 48. It will be noted further that this marginal edge of each bridging element 42, 43, 44, 46, 47 and 48 is provided with a centrally dis-posed tongue-like projection 42a, 43a, 44a, 46a, 47a, or 4811 which corresponds in shape to slots 37. Spaced at opposite sides of each projection are a pair of short slits 50 which serve to permit the marginal edge of each bridging element to yield downwardly slightly so an egg or other similar fragile article may be pushed past such overhanging bridging element portion into one of the pockets A or B formed in the set-up carton 41, adjacent the particular bridging element, see FIGS. 2 and 3. The upper end of each pocket is provided with an opening which is normally smaller than the width of the egg or article being deposited into the pocket and thus, once the egg is positioned in the pocket, the inherent resiliency of the fibreboard or cardboard will cause the marginal edge of the bridging element to return to its normal overhanging position wherein the upper open end will be of such size as to prevent the egg from accidentally falling out of the pocket in the event the box is inverted or tilted while being handled.

It will be noted in FIG. 1 that formed in spaced relation along foldlines 11a and 11b are a. plurality of tabs 51 and 52, respectively, which are struck out from center section 14. When the blank is set up to form a carton 41, the tabs 51 and 52 will overlie the outer surface of folded end portion 28a, 30a, 31a, 32a, 33a, 34a, 35a or 36a of each divider panel and resiliently retain same against the inside surface of the downwardly extending end portions of the respective bridging element, see FIG. 4.

Each bottom panel 16 may be provided with a plurality of push-up tabs 53 which are adapted to facilitate removal of the eggs from the carton pockets. The tab 53, when pushed up, will engage the underside of the accommodated egg or article and raise same so that the top of the egg or article will project up through the upper open side of the carton whereupon such egg or article can be readily grasped for further removal. In view of the upper side of each pocket being cut downwardly a substantial amount adjacent the side wall 15, the egg or article accommodated therein may be readily grasped and pulled upwardly without resorting to push-up tabs 53.

The partition walls or panels 17, when the carton is formed, are adapted to assume an upright position, see FIG. 2, and engage the depending divider panels 28, and 30-36. Each partition panel 17 is of like construction and has the outer or upper peripheral edge thereof provided with a plurality of spaced notches 54. It will be noted in FIG. 1 that certain of said notches terminate in angularly extending slits 55 wihch, in turn, lead to apertures 56 formed in walls 17. The angular disposition of the slits 55 are to provide a more positive locking action between the depending divider panels and the partition .panels, in a manner to be described more fully hereinafter.

To give added strength to the side, bottom and partition walls 15, 16, and 17 respectively, a plurality of spaced stiffening beads or ribs 57 are provided which extend transversely to the foldlines 11a-b, 12a-b, and 1311-12, see FIG. 1. Thus with such beads or ribs, a sturdy carton may be attained, notwithstanding that relatively thin fibreboard or cardboard is utilized in forming the blank.

Because of the arrangement of the slits and foldlines, the blank 10 may be readily set up, either manually or mechanically to form the carton 4 1. In setting up the carton, side walls 15 are folded downwardly along foldlines Ila-b and simultaneously therewith the opposite ends of the bridging elements are urged together whereby such opposite ends will automatically bend downwardly about foldline portions 18e, and Zea-26:2 as axes causing the divider panels to assume their depending positions. As the divider panels assume their depending positions, the side walls 15 will be folded outwardly a slight amount causing tabs 51 and 52 to project inwardly towards each other a sufficient amount so that the end portions 28a, and 30a-36a of the divider panels will pass thereover and engage the adjacent inside surfaces of the downwardly disposed end portions of the corresponding bridging elements. Once the end portions of the divider panels have assumed such positions relative to the corresponding bridging elements, the side walls 15 are then swung towards one another causing the tabs 51 and 52 to resiliently overlie and engage said divider panel end portions, see FIG. 4.

The partition walls 17 are then brought to upright back-to-back position so that the upper (or outer) peripheral portions thereof will engage the lower marginal portions of the depending divider panels. Care should be exercised in aligning the notches 54 of the partition walls 17 With the respective slots 37 of the depending divider panels. The slits 55 formed in the marginal portions of the partition walls 17 will permit portions of divider panels 30, 32, 34 and 35, disposed between slots 37 and apertures 38 to pass therethrough until the slits 55 are disposed within apertures 38, see FIG. 3. Thus, an effective interlocking relationship is established between the divider panels and the partition walls and by reason of the angular disposition of the slits 55 disengaging the partition walls from the divider panels becomes difficult without causing rupture or tearing of the blank. Once the partition walls 17 have assumed their upright positions, the bottom walls 16 assume inclined convergent relation, whereby foldlines 13a-b are the only portions of the carton which engage the supporting surface upon which the carton will rest.

As aforementioned carton 41 may be separated along line 49 into complemental carton sections 41a and b, see FIG. 3. By reason of the disposition of divider panels 32 and 33 and the foldline portions 22a and 23a being adjacent one another, each divider panel 32 or 33 will be recessed from one end of the complemental section 410 or 4115. It will be noted in FIG. 3 by reason of this recess, each partition wall will have a portion 17a thereof disposed between divider panel 32 or 33 and the end of the carton section which will prevent divider panel 32 or 33 from bulging or bowing outwardly when an egg or similar article is accommodated in the pockets formed in part by panels 32 and 33. It will be noted in FIGS. 2 and 4 that similar portions 1715 are formed in the opposite ends of partition walls 17 which serve the same purpose for end divider panels 28 and 36. The complemental sections 41a and 41]; are possessed of the same structural rigidity and sturdiness as the whole carton 41. Because of the rigidity of the whole carton, separation thereof into the complemental sections is readily accomplished in a manner as illustrated in FIG. 3 regardless of whether the carton be loaded or empty.

In the complemental carton sections 41ab as well as in the whole carton 41, the pockets A and B formed therein are of uniform configuration and an overhanging marginal portion of a bridging element is provided for each pocket so as to retain the accommodated egg or article in position within the carton or carton sections.

Because of the angular disposition of the side and bottom Walls and 16 in the set-up carton, the accommodated egg or article is provided with point, or line, contact support with portions of the side and bottom walls adjacent foldlines Eta-b serving to hold the accommodated egg or article in spaced relation with respect to the surface upon which the carton or carton section rests.

It will be observed in FIG. 1, that the blank design is such as to afford efficient use of the blank material. An extremely small amount of material waste is occasioned in forming the blank 10. By rendering the carton 41 separable no excessive amount of blank material is required and the carton sections 41a and b are of substantially the same construction at both ends.

Thus, it will be seen that an improved separable foldable carton is provided which effectively overcomes the problems which had heretofore beset the prior art structures. The improved carton is formed from a blank wherein there is a minimum of material waste, and yet the blank is readily capable of being set-up to form a carton possessed of a high degree of structural stability and strength.

While a particular embodiment of this invention has been shown, it is to be understood, of course, that such invention is not limited thereto, as modifications thereof are contemplated and such modifications are intended to come Within the scope of the claims appended hereto.

I claim:

1. An elongated foldable carton for eggs and the like, comprising a pair of elongated side panels arranged in spaced substantially coextensive relation, bottom panels extending angularly from the lower marginal portions of said side panels, elongated partitioning means disposed intermediate said side panels and extending upwardly from said bottom panels, a plurality of bridging elements arranged in spaced substantially parallel relation and interconnecting corresponding segments of the upper marginal portions of said side panels, and a plurality of divider panels depending from said bridging elements and cooperating with said side and bottom panels and said partitioning means to form rows of egg-accommodating pockets, peripheral end portions of each divider panel being in interlocking engagement with portions of the respective bridging elements and said partitioning means and retaining said divider panels in depending relation with respect to said bridging elements; one of said bridging elements intermediate the end bridging elements being provided with a pair of spaced substantially parallel divider panels, said one bridging element and the portions of said side and bottom panels and the partitioning means disposed intermediate the planes of said pair of divider panels being provided with means whereby said carton is separable into complemental carton sections and each divider panel of the separated pair of divider panels has the peripheral end portions thereof in interlocking engagement with portions of the separated bridging element and becomes an end face of a complemental carton section.

2. The carton recited in claim 1 wherein one of the bridging elements disposed adjacent each of said pockets has a portion thereof projecting toward the adjacent bridging element and extending partially over said pocket, sai-d bridging element projecting portion having a resilient segment cooperating with the adjacent bridging element to form a restricted opening whereby an egg accommodated in said pocket is restrained from accidental discharge from said pocket upon said carton assuming an inverted position.

3. The carton recited in claim 1 wherein each divider panel has opposed marginal portions angularly offset and disposed in substantial face to face contact with portions of the bridging element from which said divider panel depends, each bridging element is provided with locking means engaging and retaining said marginal portions in said face to face contact.

4. An elongated foldable carton for eggs and the like, comprising a bottom, a pair of elongated side panels extending upwardly from said bottom, a plurality of elongated bridging elements arranged in spaced substantially parallel relation and interconnecting corresponding segments of the upper marginal portions of said side panels, and a plurality of divider panels depending from said bridging elements and cooperating with said side panels and said bottom to form a row of egg-accommodating pockets, peripheral end portions of each divider panel being in interlocking engagement with end portions of the bridging element from which said divider panel depends and retaining said divider panels in depending relation with respect to said bridging elements; one of said bridging elements intermediate the end bridging elements being provided with a pair of spaced substantially parallel divider panels, said one bridging ele ment and the portions of said side panels and bottom disposed intermediate the planes of said pair of divider panels being provided with means for separating said carton into complemented carton sections whereby each divider panel of the separated pair of divider panels has the peripheral end portions thereof in interlocking engagement with the end portions of the separated bridging element and becomes an end face of a complemental carton section.

5. The carton recited in claim 4 wherein the bridging elements disposed on each side of said one bridging element have the divider panels thereof depending from the elongated peripheral sides of said bridging elements farthest removed from said one bridging element.

6. An elongated foldable carton for eggs or the like comprising a bottom, upstanding sides connected thereto, a partition disposed intermediate said sides and extending longitudinally of said carton and projecting upwardly from said bottom, a plurality of relatively spaced substantially parallel bridging elements overlying the top of said carton and interconnecting corresponding upper marginal portions of said sides, said bridging elements being disposed substantially transverse to the longitudinal axis of said carton, and a plurality of divider panels depending from said bridging elements and having peripheral end portions of said divider panels interlockingly engaging end portions of said bridging elements and peripheral central portions of said divider panels interlockingly engaging said partition to form parallel rows of egg-accommodating pockets, the divider panels depending from the end bridging elements forming recessed end walls for said carton; one of said bridging elements intermediate said end bridging elements having a pair of spaced substantially parallel divider panels depending from opposed sides thereof; the portions of said one bridging element, said bottom, said sides, and said partition disposed intermediate the planes of said pair of divider panels beng provided with means whereby said carton may be separated into complemental carton sections and each divider panel of the separated pair of divider panels has the peripheral end portions thereof in interlocking engagement with the end portions of the separated bridging element and the central portion thereof in interlocking engagement with the separated partition and forming an end wall of a carton section.

7. The carton recited in claim 6 wherein a bridging element adjacent each egg-accommodating pocket has a portion thereof projecting toward an adjacent bridging element and extending partially over said adjacent pocket, said bridging element projecting portion having a resilient segment which cooperates with the adjacent bridging element to form a restricted opening whereby an egg accommodated within said adjacent pocket is restrained from accidental discharge from said pocket upon said carton assuming an inverted position.

8. A carton blank formed of foldable sheet material comprising an elongated top-forming first section, a pair of elongated side-forming second sections foldably connected to the elongated opposite sides of said first section, a pair of elongated bottom-forming third sections foldably connected to the sides of said second sections opposite those sides to which said first section is connected, and a pair of partition-forming fourth sections foldably connected to the sides of said third sections opposite those sides to which said second section are connected; said first section being provided with a plurality of slits which define a plurality of divider panels, each of which has a peripheral segment thereof foldably connected to the remainder of said first section whereby each divider panel automatically assumes a depending position with respect to said first section upon said blank being set up to form a carton; said first section being further provided with a plurality of foldable tabs, the line of fold of each tab being substantially coincident to a line of fold connecting said first and second sections; said tabs being engageable with said divider panels and retaining same in their depending positions upon said blank being set up to form a carton; said first, second, third, and fourth sections being provided with coaxially aligned weakening scores angularly disposed relative to the fold connections between said sections whereby the set-up carton may be formed into complemental carton sections along said weakening scores.

9. The blank recited in claim 8 wherein the lines of fold between said sections are disposed in substantially parallel relation, and folding connections for said divider panels, are disposed substantially perpendicular to said section foldlinesv 10. The blank recited in claim 8 wherein said aligned weakening scores are disposed substantially normal to the lines of fold between said sections.

11. The blank recited in claim 10 wherein the weakening score formed in said first section extends between two of said divider panels and the lines of fold of said two divider panels are adjacent and substantially parallel to Said weakening score.

References Cited by the Examiner UNITED STATES PATENTS 5/1963 Levkoff 229--28 9/ 1963 Sheldon-Williams 229-28 

1. AN ELONGATED FOLDABLE CARTON FOR EGGS AND THE LIKE, COMPRISING A PAIR OF ELONGATED SIDE PANELS ARRANGED IN SPACED SUBSTANTIALLY COEXTENSIVE RELATION, BOTTOM PANELS EXTENDING ANGULARLY FROM THE LOWER MARGINAL PORTIONS OF SAID SIDE PANELS, ELONGATED PARTITIONING MEANS DISPOSED INTERMEDIATE SAID SIDE PANELS AND EXTENDING UPWARDLY FROM SAID BOTTOM PANELS, A PURALITY OF BRIDGING ELEMENTS ARRANGED IS SPACED SUBSTANTIALLY PARALLEL RELATION AND INTERCONECTING CORRESPONDING SEGMENTS OF THE UPPER MARGINAL PORTIONS OF SAID SIDE PANES, AND A PLURALITY OF DIVIDER PANELS DEPENDING FROM SAID BRIDGING ELEMENTS AND COOPERATING WITH SAID SIDE AND BOTTOM PANELS AND SAID PARTITIONING MEANS TO FORM ROWS OF EGG-ACCOMMODATING POCKETS, PERIPHERAL END PORTIONS OF EACH DIVIDER PANEL BEING IN INTERLOCKING ENGAGEMENT WITH PORTIONS OF THE RESPECTIVE BRIDGING ELEMENTS AND SAID PARTITIONING MEANS AND RETAINING SAID DIVIDER PANELS IN DEPENDING RELATION WITH RESPECT TO SAID BRIDGING ELEMENTS; ONE OF SAID BRIDGING ELEMENTS INTERMEDIATE THE END BRIDGING ELEMENTS 